Sound absorbing structural block with through passage and transverse baffles



March 1, 1966 sURlNE 3,237,714

R. SOUND ABSORBING STRUCTURAL BLOCK WITH THROUGH PASSAGE AND TRANSVERSE BAFFLES Filed Feb. 17, 1964 RZM United States Patent 3,237,714 SOUND ABSORBING STRUCTURAL BLOCK WITH THROUGH PASSAGE AND TRANS- VERSE BAFFLES Raymond L. Surine, 4173 Buttrick Road, Ada, Mich. Filed Feb. 17, 1964, Ser. No. 345,284 8 Claims. (Cl. 181-33) This invention relates to a structural block unit, and more particularly to a block having controlled acoustical characteristics and unusual aesthetic beauty, as well as structural qualities.

Modern style architecture, although highly unique in many respects, is often limited in the number of actual different structures which can be practically achieved. This is often due to the lack of structural components capable of being formed into unusual assembled configurations, while also maintaining proper structural capacity, aesthetic attraction, and interior acoustical characteristics.

The inability to achieve proper acoustical characteristics is especially troublesome when employing interfitting, like, blocks of solid or near solid construction. Various types of attachable acoustical paneling has been devised for use on the hard interior surface of conventional blocks to improve the acoustics. However, this causes a significant additional expense. It moreover adds complexity to the design, and often hides other architectural features.

Then too, not only do acoustical characteristics vary greatly and uncontrollably with the arrangement of blocks, but each type and size of building structure has different acoustical requirements depending upon its intended use.

It is, therefore, an object of this invention to provide a structural block capable of smoothly blending several characteristics of structural capacity, aesthetic attraction, and proper acoustical characteristics into one functional whole of optimum, controlled characteristics. The block can be employed with equal effectiveness in buildings of different types, sizes and configurations. It allows architects to achieve unusual configurations and arrangements without undue concern for proper acoustical values since these can be readily obtained by simple adjustment of the units in the completed structure. The very nature of the novel type block contributes to aesthetic qualities since the block itself is appealing, as well as an assembly of the blocks.

Another object of this invention is to provide an acoustical structural block having excellent thermal insulating qualities, while simultaneously allowing variations in light entrance control, and acoustical control. Not only the quantity of light entry is controllable, but also the nature of the light, specifically in color pattern effects over the entire building surface. Consequently, the mood of the building can be determined to match its purpose.

Another object of this invention is to provide a struc tural building block capable of simultaneously forming a completed, finished, attractive, interior surface, while also forming a complete exterior surface, without additional materials being necessary. Both sides have aesthetic appeal, light entry control, acoustical variation control, and weather tightness. Moreover, the assembly of blocks can be self-supporting, and if desired, can be free standing. Alternatively, the blocks can be employed with additional support structure, and/or interior panel- Another object of this invention is to provide an acoustical block having a completely controllable acoustical quality, yet with a relatively inexpensive and a very practical construction. The acoustical characteristics of each block can be individually adjusted before or after installation, to enable exact acoustical results to be obtained. Yet this can be done without detracting from the appearance of the units or the assembly. The acoustical characteristics can be pre-set to desired reverberation values on a mathematical basis.

These and several other objects of this invention will become apparent upon studying the following specification in conjunction with the drawings in which:

FIG. 1 is a side elevational view of a first form of the inventive block structure;

FIG. 2 is a sectional view of the block in FIG. 1;

FIG. 3 is a top plan view of the block in FIG. 1;

FIG. 4 is an exploded, perspective View of the block in FIGS. 1, 2, and 3;

FIG. 5 is a sectional view of a second form of the inventive block;

FIG. 6 is an exploded, perspective view of the block in FIG. 5;

FIG. 7 is a sectional view of the third form of the inventive block;

FIG. 8 is a bottom view of the block in FIG. 7;

FIG. 9 is a perspective view of a fourth form of the inventive block but without its bafiles in place;

FIG. 10 is a perspective view of a fifth form of the inventive block of a different configuration;

FIG. 11 is a sixth form of the inventive block; and

FIG. 12 is a seventh form of the inventive block.

Referring now specifically to the drawing, these seven different forms of the structure are illustrated to show various features, but each may have various features in combination from the others as will be understood from the complete description to follow. For example, the variations can be in the structure for locating the interior baflles, in the internal and/or external geometrical configuration, in the use or non-use of insert elements, and in the number and size of openings in the block.

Referring specifically to the first form of the invention shown in FIGS. 1, 2, 3 and 4, the complete block assembly 10 includes a basic body element 12 of rigid, sturdy construction. The body element is a peripheral shell which forms a continuous peripheral surface 14 which, in this instance, is frusto-conical. The shell may be formed of any suitable rigid structural material usually concrete, plaster or wood, but also of rigid foam plastic or of a resin shell, depending upon the strength necessary. Conceivably, other materials could be employed, provided it can be molded, cast, machined or otherwise formed into the desired shell configuration. The particular dimensions of the block can vary widely as long as the desired structural capacity of the block is maintained.

The block has two opposite faces 16 and 18 as well as the peripheral surface 14. These two faces will normally be an outer face 16 and an inner face 18. Extending completely through the block between these two faces is a through passage having an inner peripheral wall 20 (FIG. 4). Positioned Within this passage are at least two spaced, transverse baffles 22 and 24 having a width diameter sufiiciently large to engage the complete periphery of the passage to engage the inner wall. These bafiles may be in direct engagement with the wall 20 of the block material itself, or may alternatively be engaged with insert elements. Each baffle is preferably solid, but in the broader aspects could conceivably be perforated.

Preferably, a pair of inserts 28 and 30 are employed in the passage to reinforce the block and also locate the bafiles at exact locations along the block axis. Thus, larger diameter annular insert 28 lines peripheral Wall 20 and forms its own inner peripheral wall. Preferably, the outside baffle 22 fits against the end of this hollow, frusto-conical insert 28. The baffle is secured in position by any suitable means such as a sealing resin or other adhesive or securing means. Positioned within this insert 28 is the smaller frusto-conical insert 30 which fits smoothly in the outer insert. It serves as a locator for Elie slecond baffie 24 which is intermediate the faces of the oc r.

In the form of the invention illustrated in FIGS. 1 through 4, the outer bafiie 22 forms part of the outer face 16, since it is flush with this end of the block. The second baffle 24, however, is intermediate the faces of the block, thereby leaving an open recess or pocket 36 in the inner face 18 of the block. This pocket has definite acoustical advantages when face 18 is used to help form the finished inner surface of a build-ing construction. It collects and absorbs reverberations to optimize acoustical effects.

The dead air space 40 between the two bafiies provides a thermal insulating effect. This dead air space is preferably not filled with additional insulating material, especially if baffles 22 and 24 are made of a transparent or translucent material for light transmission as explained hereinafter. However, insulating material can be inserted in some instances if necessary.

Light can be transmitted through the block to achieve internal lighting of controlled amounts if the baffles are of a translucent substance. The characteristics of the translucent plastic or glass baffles can be modified by coloring, by etching or otherwise to achieve different internal lighting effects. The variations in one building can be many.

Since the passage through this block in FIG. 1 is tapered, the inserts are of different sizes to fit properly. Also, the peripheral flanges or edges of the baffles are slightly tapered to interengage neatly with the surrounding wall. Accordingly, the position of the baffles can be controlled not only by their engagement with these inserts, but also by their specific diameters, to fit specific diameter portions of the passage.

To assemble the structure, the shell body 12 is first fabricated by casting, molding, machining or other forming processes, depending upon the materials employed. If inserts are to be used, these inserts are pressed into passage 20, first insert 28 and then insert 30. These are secured in place by adhesives, by a pressed fit, or as otherwise necessary. Then the two bafiies 24 and 22 are inserted and secured in position to define the acoustical cavity and the insulating dead air space 40. The unit is then ready for assembly with other like or basically similar blocks, either with or without additional structural support.

In many instances it is extremely difficult to exactly calculate the resulting acoustical characteristics of a building prior to construction, especially if it is to be of unusual con-figuration, or if the acoustics are unusually important. In these instances, it would be definitely advantageous to allow acoustical adjustment and variation after assembly. With the novel block, this can be achieved readily and quickly with controlled adjustment of the inner baffle 24, to thereby achieve controlled acoustical characteristics by varying the depth of cavity 36. Referring to FIG. 5, the form of the invention like here shown was devised to achieve this. In this form of the invention, the complete assembly 110 includes the shell body 112 of like characteristics to those described with respect to FIG. 1.

Here, however, the passage is of like cross section over a substantial portion, and if necessary, over its entire length. For example, it may be cylindrical. If desired, an insert 128 of cylindrical configuration fits the cylindrical peripheral wall of the passage. This insert not only lines and structurally reinforces the block surface, but also serves as a locator for outer baffle 122. The inner bafiie 124 in this instance, however, is not for-med with a fit inside the block so tight as to be permanently secured, but rather is 'slidably movable along the cylindrical passage. Its location in any one particular adjusted position can be maintained as by a sliding friction seal 125, generally .annular in configuration. It has a first annular leg'which lies in one plane for attachment to bafiie 124. Its second leg is cylindrical in configuration and lies against the inner periphery of insert 128. This element may be formed of suitable plastic leather, rubber or other like material to provide a sliding, holding fit in the block. It is preferably an annulus to allow light to be transmitted through the two baflies as previously explained. This is only one type of interfit since it will be realized that the baffle periphery itself may have a sliding. fit with the block without an additional element.

It will be readily realized that even after blocks like those illustrated in FIG. 5 are assembled, the individual baffles 124 in each adjacent block can be carefully'regulated prior to insertion of bafiie 122 to achieve optimum acoustical effects over every portion of the building construction.

Assembly of the form of the invention illustrated in FIG. 5 is shown specifically in FIG. 6 in exploded view. After forming the components, they are assembled by inserting the sleeve 128 into the cylindrical periphery of the block shell 112, then inserting inner bafile 124 and its sliding locator sleeve 125, and finally inserting outerbafile 122 into the countersunk recess 123 at the end of the passage adjacent the outer face 116.

Another form of the invention, the third form, similar to the second form in FIG. 5, but without the inner inserts is illustrated in FIGS. 7 and 8. In this form of the invention, the inner bafiie 124' and its sliding seal 125 fit directly against peripheral wall 120 to achieve a sliding fit thereon. The outer baffle 122 in this instance is of slightly larger diameter than the passage and fits in a countersink at the end of the passage, to be flush with the outer face 116. Its function is like that of the structure in FIG. 5. The complete construction of this block is illustrated from the inner face in FIG. 8, including inner bafiie 124, inside face 118, and peripheral block surface 114 of generally frusto-conical external configuration.

Instead of employing inserts or friction elements as locators, the baffles may be located in fixed positions by countersinking the passage to varying depths and diameters as illustrated in FIG. 9. In this instance, block shell 212 includes a first shallow larger diameter countersink 223 adjacent the outer face, and a second deeper, smaller diameter, elongated countersink 227 extending part way to the inner face of the shell. Consequently, the inner baflile will rest in the second countersink, and the outer bafile in the first countersink, both to be secured in fixed position according to a predetermined calculated spacing. This is to achieve. an exact controlled acoustical cavity on the inner diameter portion 220' of passage for acoustical purposes.

It will be readily realized that the particular configurations of the structure may be widely varied. In the first three forms of the invention illustrated in FIGS. 1 through 8, the out'er'peripheral surface of the block is frusto-conical, but in FIG. 9, the peripheral surface is cylindrical.

In FIG. 10, body shell 312 has-a peripheral configuration and surface 314 square in cross section. Preferably, its inner passage, as well as its double countersink (similar to that in FIG. 9) are also square in configuration to receive square baffies. Of course, the square outer peripheral surface can be combined with a round inner passage and bafiies, or vice versa. Further, many other different configurations can be used such as the triangular configuration shown for the outer surface 414 of shell 412 in FIG. 12, and its triangular passage and inner periphery 420.

In FIG. 11, a slightly modified concept is shown, in which the polygonal block has a hexagonal polygon shell 512 with several passages extending from outer face 516 to inner face 518. It will be realized that peripheral Walls 514 may be tapered from one end to the other or may be untapered so that the outer face of the block Is the same as or different from the inner face dimension. In this instance, the openings are shown to be triangular in configuration, being six in number corresponding to the six side wall portions, and separated by shell partitions 512'. Likewise, these triangular openings include a first countersink 523 and a second countersink 527 for location of the baflies to be inserted therein. Again, it should be realized that the inserts similar to those in FIGS. 2 and 5 can be employed in this construction. If the passages are of like dimension over a portion of their length, an adjustable inner bafiie can be employed utilizing a structure similar to that in FIG. 5 or FIG. 7.

Consequently, the several features illustrated in separate form can be combined in any number of variations too numerous to depict in this application, and readily understood by those having studied this specification. Likewise, the outer surface or the inner surface or both need not be exactly flat, but can be slightly concave or slightly convex as illustrated by the outer face 516 in FIG. 11. Several outer surfaces, or inner surfaces, may collectively form a segment of a sphere, a cylinder (of variable size radii), a free form surface with a multitude of different radii, just a flat surface, or any of several other possibilities. The essential components of the combination are the rigid shell forming the main support body with an enclosing peripheral surface, the passage extending through the block from the inner face to the outer face, and the spaced baffle means in the passage, especially with the inner baffle forming a controlled acoustical recess and the outer baflie preferably flush with the outer face, to also define a thermal insulating space between the baffles. With these basic components, the variations are many and the architectural possibilities are almost limitless. Various other modifications in detail will occur to those skilled in this art to suit different applications, once the concept set forth herein is comprehended. Consequently, in view of the many variations possible, this invention is not to be limited to the specific preferred illustrative forms depicted, but only the scope of the appended claims, and the reasonable equivalents thereto.

I claim:

1. A structural block for combination with other like blocks, comprising: an integral, peripheral body shell of rigid, sturdy material forming a closed peripheral outer surface for cooperative association with other like blocks and two end faces; said shell having at least one central opening therein, extending completely through said block between said faces to have both ends open; and spaced transverse insert baffies retained within said opening, extending thereacross and closing off said opening in at least two selected positions; the baflie adjacent one end face being recessed therefrom to form a dead end cavity of controlled acoustical characteristics.

2. A structural block for combination with other like blocks, comprising: an integral, peripheral body shell of rigid, sturdy material forming a closed peripheral outer surface for cooperative association with other like blocks and two end faces; said shell having at least one central opening therein, extending completely through said block between said faces to have both ends open; and spaced transverse insert baffles retained within said open ing, extending thereacross and closing off said opening in at least two selected positions; the baffle adjacent one end face being recessed therefrom to form a dead end cavity of controlled acoustical characteristics; and said baffles being solid and forming a thermal insulating space therebetween.

3. A structural block for combination with other like blocks, comprising: an integral, peripheral body shell of rigid, sturdy material forming a closed peripheral outer surface for cooperative association with other like blocks and inner and outer end faces; said shell having at least one central opening therein, extending completely through said block between said faces to have both ends open; a pair of spaced transverse insert baffies retained within said opening, extending thereacross and closing off said opening at two selected positions; and said baffles both being translucent, enabling controlled light transmission through said block from said outer face to said inner face.

4. A structural block for combination with other like blocks, comprising: an integral, peripheral body shell of rigid, sturdy material forming a closed peripheral outer surface for cooperative association with other like blocks and two end faces; said shell having at least one central opening therein, extending completely through said block between said faces to have both ends open; and spaced transverse insert bafiles retained within said opening, extending thereacross and closing off said opening in at least two selected positions; the bafiie adjacent one end face being recessed therefrom to form a dead end cavity of controlled acoustical characteristics; and said recessed baffle being manually adjustable along said opening to effect acoustical control of said block at all times.

5. The block in claim 4 wherein said opening has a portion of like cross section, around said adjustable baffle, and said adjustable baffle includes slidable seal and frictional holding means adjacent its periphery, abutting the periphery of said opening.

6. A structural block for combination with other like blocks, comprising: an integral, peripheral body shell of rigid, sturdy material forming a closed peripheral outer surface for cooperative association with other like blocks and inner and outer end faces; said shell having at least one central opening therein, extending completely through said block between said faces to have both ends open; a pair of transverse, spaced insert baffles retained within said opening, extending thereacross and closing off said opening at two selected positions; at least the baffle adjacent said inner end face being recessed therefrom to form an inner-face, dead end cavity of controlled acoustical characteristics; said baffles forming a thermal insulating space therebetween; and insert liner means in said opening, abutting at least one of said baffles and forming locator means for said bafile.

7. A structural block for combination with other like blocks, comprising: an integral, peripheral body shell of rigid, sturdy material forming a closed peripheral outer surface for cooperative association with other like blocks and end faces; said shell having central opening means extending through said block between said faces to form a passage with both ends open; spaced insert baffle means within said opening means, extending thereacross at selected positions; the baffle adjacent one end face being recessed therefrom to form a cavity of acoustical absorbing characteristics; said passage having portions of different diameter, and said baffles having different diameters corresponding to pre-selected passage portions, to interfit therewith for locating said baffles.

8. The block in claim 7 wherein said passage is tapered from one end face to the other.

References Cited by the Examiner UNITED STATES PATENTS 1,075,128 10/1913 Skinner. 2,130,285 9/1938 Marqua 50-101 X 2,159,991 5/1939 Hilpert 18133 2,426,796 9/ 1947 Stadelhofer. 2,745,276 5/ 1956 Ku'hlman 50-458 FOREIGN PATENTS 552,826 2/ 1958 Canada. 1,054,377 10/ 1953 France. 1,181,608 1/1959 France.

434,127 8/ 1935 Great Britain.

LEO SMILOW, Primary Examiner. 

1. A STRUCTURAL BLOCK FOR COMBINATION WITH OTHER LIKE BLOCKS, COMPRISING: AN INTEGRAL, PERIPHERAL BODY SHELL OF RIGID, STURDY MATERIAL FORMING A CLOSED PERIPHERAL OUTER SURFACE FOR COOPERATIVE ASSOCIATION WITH OTHER LIKE BLOCKS AND TWO END FACES; SAID SHELL HAVING AT LEAST ONE CENTRAL OPENING THEREIN, EXTENDING COMPLETELY THROUGH SAID BLOCK BETWEEN SAID FACES TO HAVE BOTH ENDS OPEN; AND SPACED TRANSVERSE INSERT BAFFLES RETAINED WITHIN SAID OPENING, EXTENDING THEREACROSS AND CLOSING OFF SAID OPENING IN AT LEAST TWO SELECTED POSITIONS; THE BAFFLE ADJACENT ONE END FACE BEING RECESSED THEREFROM TO FORM A DEAD END CAVITY OF CONTROLLED ACOUSTICAL CHARACTERISTICS. 